Maintenance Schedule - Squarespace

Maintenance Schedule

MAN Marine Diesel Engines

V8 / V12

Light Duty

51.99597-8044 “Translation of the original instructions”

Printer's imprint

MAN marine diesel engines D2868 LE4.. / D2862 LE4..

2

Maintenance Schedules for Light Duty

Subject to technical alterations in the interests of further development.

Reprinting, copying or translation, even of extracts, is not allowed without the written approval of

MAN Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN.

© 2013

MAN Engines

A Division of MAN Truck & Bus AG

Vogelweiherstrasse 33

D - 90441 Nürnberg

email: [email protected]

Internet: www.man-engines.com

Editorial: EMDGG, 02.2013

51.99597-8044

Data on drive system and boat

1

1. Name and address of owner

2. Data on drive system

3. Engine model: 4. Output in kW / rpm:

5. Works number: 6. Date of commissioning:

7. Engine number

Starboard engine:

rpm (important note overleaf)

8 Engine number

Port engine:

rpm (important note overleaf)

9. Name of MAN agent,

Date, Signature:

10. Boat details

11. Boat type:

12. Boat name:

13. Boat number,

Year of construction:

2

Foreword

MAN Marine Diesel Engines D2868 LE4.. / D2862 LE4..

3

Maintenance Schedule for Light Duty

1 Foreword

1.1 Validity of the Maintenance Schedule

This manual is an overview of all the required maintenance operations which are to be performed at regular

intervals on the V8 and V12 marine main propulsion engines from the model series

D 2868 (V8) / D2862 (V12) for "Light Duty".

The respective application type "Light Duty" is specified by the rated speed of 2300 rpm, which is recorded

on the number plate of the engine.

Maintenance operations are to be performed as per the maintenance schedule on page 7 after a certain

number of operating hours by a MAN authorised workshop.

1.2 Important information

Important information is necessary to operate and maintain the MAN propulsion system. For this reason

the following publications must always be at hand:

� Operating Instructions

� Fluids and Lubricants for MAN Diesel Engines

� Spare Parts Catalogue

If you should require any assistance, you can find a current list of service centres on the Internet at:

http://www.man-engines.com/ � Marine engines � Service � Service centres

Our representatives will be happy to assist with any questions you may have which cannot be clarified by

the information contained in these publications. Please have the following information at hand: the 14-digit

engine number. This is entered on the “Data on drive system and boat" form on page 1, on the engine's

model plate or in the documents at your shipyard.

Sincerely,

MAN Engines

A Division of MAN Truck & Bus AG

Nuremberg Works

Maintenance Work


4


2 Maintenance Work

2.1 Maintenance Schedule

Maintenance operations are to be performed after the corresponding number of operating hours has been

reached or at least once per year, see the maintenance schedule, page 7.

The Maintenance Schedule consists of the basic services M1, M2 and M3 every 400 hours of operation

and additional work M4 dependent on the running hours.

If the relevant operating hours are not reached within one year, the maintenance work is to be performed

annually.

2.2 General information on performing service work

Every maintenance operation is recorded in the “Maintenance Record" section of this book (either accord

ing to the operating hours or the annual intervals).

At each service inspection, the MAN authorised workshop is to confirm the correct performance of the work

according to the maintenance schedule with a stamp and a signature.

Make sure that all entries are legible, complete and have been properly made.

After each service inspection the engine is to be test driven to determine the engine speed which can be

reached at full load (max. ship speed). This value should not be less than the rated speed (see model

plate). This test is valid as proof for the maximum engine power.

Conditions for engine speed test:

� Ship loaded (tanks filled, equipment on board)

� No growth on hull, propeller and shaft system

2.3 Commissioning

As part of the commissioning the “Data on drive system and boat" form, page 1, is to be filled out by the

authorised workshop.

2.4 Daily inspection

A daily inspection has to be performed as part of the board routine:

� Engine oil level / transmission oil level

� Coolant level in expansion tank

� Operation of instruments

� Visual inspection of engine for oil and coolant leaks

� Drain water from fuel filters and fuel pre-filters

General Notes on Maintenance Work


5


3 General Notes on Maintenance Work

3.1 When performing maintenance work

DANGER

Risk of injury and scalding!!

Therefore:

� Carefully read the safety regulations in the Operating Instructions!

NOTE

No liability for engine damage if non-approved spare parts are used.

Therefore:

� Use only genuine MAN spare parts. MAN will accept no responsibility for damage resulting from the

installation of other parts from external sources.

� Exchange worn seals.

� Tighten screwed connections for which tightening torques are specified (see “Service Data"), always

using a torque wrench.

� Clean removed parts before refitting them, and check them for damage unless exchange is mandatory.

3.2 When checking the engine oil level or changing the engine oil

NOTE

No liability for engine damage if non-approved fuels, lubricants and fluids are used!

If non-approved fuels, lubricants and fluids are used, MAN accepts no liability for material damage.

Therefore:

� Only use approved fuels, lubricants and fluids (see publication “Fluids, Lubricants and Coolants for

MAN Industrial and Marine Diesel Engines"). A current list of approved products can be found online

at: https://mmrepro.mn.man.de/bstwebapp/BSTServlet

� The procedure for changing engine oil and oil filters is described in the Operator's Manual in the chapter

”Maintenance and care".

� Keep vicinity of filler orifices and of dipsticks clean, so that no dirt can get into the oil pan.

� Caution: Do not fill up with oil beyond the max. notch on the dipstick.

Overfilling causes damage to engine.

� If loss of oil is due to leaks, ascertain and eliminate cause.

3.3 When checking the coolant level

� Top up with missing quantity of fluid, ensuring that the concentration of the antifreeze / anti‐corrosion

agent is correct (see Operating Instructions, chapter ”Maintenance and care" and the publication ”Fuels,

Lubricants and Coolants for MAN Diesel Engines").

� Ascertain and eliminate cause of loss of coolant.

3.4 When changing the coolant

� Drain and fill up with coolant and bleed cooling system as described in the Operating Instructions, chap

ter ”Maintenance and care".

� For antifreeze / anti‐corrosion agents see publication ”Fuels, Lubricants and Coolants for MAN Diesel

Engines".

General Notes on Maintenance Work


6


3.5 When checking for leaks of oil, coolant and fuel

� Carry out visual check of engine exterior (crankcase, cylinder heads etc.) for emergence of oil.

� Carry out visual check of all fluid‐containing parts (reservoirs, pipes, hoses) for leaks.

� Carry out visual check of pipes and hoses to see whether they are correctly routed or show chafing

marks.

3.6 When checking the turbochargers

Carrying out a visual inspection of turbochargers for:

� Traces of contact between the compressor impeller and the compressor housing

� Deformation of the blades, damage to the leading edges of the blades, due to the action of foreign bo

dies

� Condition of oil outlet in the compressor and exhaust gas housing

Testing of the turbochargers for:

� Smooth running of the rotor shaft

� Cecking of mounting bolts on the compressor rear wall and the exhaust gas housing for force fit

� Firm seating of and damage to the connections for the oil supply and return system and their sealing



7


4 Maintenance Schedule - Light Duty

The maintenance schedule 4.1 consists of the basic maintenance operations:

� M1 every 400 operating hours



The additional maintenance operations M4 are to be performed dependent on the running hours.

If the relevant operating hours for M1, M2 and M3 are not reached within one year, the maintenance work

is to be performed annually according to maintenance schedule 4.2.

4.1 Maintenance operations according to operating hours

Scope of maintenance operations for Light Duty (LD)

according to operating hours

M1 M2 M3 M4

400 x x x

800 x x

1,200 x

1,600 x x x

2,000 x

2,400 x x

2,800 x x

3,200 x x x

3,600 x

4,000 x x x

4,400 x

4,800 x x

5,200 x x

5,600 x x

6,000 x x

6,400 x x x

6,800 x

7,200 x x

7,600 x x

8,000 x x

8,400 x

8,800 x x x

9,200 x x

9,600 x x

10,000 x x

10,400 x x

10,800 x

11,200 x x x

11,600 x

12,000 x x

For Scope of maintenance operations see page 9.

Maintenance and TBO Schedule


8


4.2 Maintenance operation according to time intervals

Scope of maintenance operations for Light Duty (LD)

According to time intervals Daily inspection

M1 M2 M3 M4

Daily x

Yearly x x x

After every 4 years x

For Scope of maintenance operations see page 9.



9


4.3 Scope of maintenance operations

Basic Maintenance

Daily A daily inspection has to be performed as part of the board routine:

� Engine oil level / transmission oil level

� Coolant level in expansion tank


� Visual inspection of engine for oil and coolant leaks

� Drain water from fuel filters and fuel pre-filters

� Abnormal engine noise and smoke characteristics

M1 Checking

� Read out diagnosis system memory from EDC and MMDS

� Outside of engine for oil and coolant leaks1)

� Coolant level

� Concentration of antifreeze/anticorrosion agent

� Engine alarms


� Coolant hose for leaks

� Fuel lines and oil lines for leaks

� Condition of impeller

� Removable fasteners (screws / bolts, hose clamps, pipe connections) and tighten if necessary

� Condition of Poly-V belt

� Visually inspect engine wiring harness for damage; do not open any connections

� Resilient mounts of engine and gearbox

� Alignment of the shaft system

Reading out

� Diagnosis system memory MMDS

� Diagnosis system memory EDC and delete

Changing

� Engine oil

� Engine oil filter cartridges

� Fuel filter cartridges1)

� Fuel prefilter cartridges

� Air filters

Cleaning

� Strainer of fuel prefilter

� Sea water filter

Trial run

� Test drive, engine speed test with ship fully loaded2)

M2 Checking and setting if necessary

� Valve clearance

M3 Performing fault diagnosis

� Carry out compression test and run-up test (TCOM, TRUP)

1) The fuel filters are to be changed out earlier if the fuel is dirty or contains a high proportion of water.

2) Fully loaded means: water tank and fuel tank are filled, all ship equipment including life boats.

The above mentioned maintenance operations M1 to M3 are to be performed when the corresponding

number of operating hours has been reached or once per year (see page 7) by a MAN authorised work

shop.

Maintenance and TBO Schedule


10


Additional Maintenance

M4 Maintaining charge air and cooling system

� Visually inspect turbochargers and replace if neccessary

� Clean charge air cooler tube cluster, perform pressure test if neccessary

� Clean heat exchanger plates

� Replace coolant

� Replace all hoses for coolant and sea water

Maintenance Record


11

Maintenance Record

Maintenance Record

Maintenance Record


12

Maintenance Record

Maintenance Record


13

Maintenance Record

400Location

Performed at operating hours

Invoice number

Product name of engine oil / viscosity class

Max. engine speed as tested(starboard engine)

Max. engine speed as tested(Port engine)

Next maintenance(date and/or operating hours)

Stamp, Date, Signature

800Location


Invoice number






Maintenance Record


14

Maintenance Record

1200Location


Invoice number






1600Location


Invoice number






Maintenance Record


15

Maintenance Record

2000Location


Invoice number






2400Location


Invoice number






Maintenance Record


16

Maintenance Record

2800Location


Invoice number






3200Location


Invoice number






Maintenance Record


17

Maintenance Record

3600Location


Invoice number






4000Location


Invoice number






Maintenance Record


18

Maintenance Record

4400Location


Invoice number






4800Location


Invoice number






Maintenance Record


19

Maintenance Record

5200Location


Invoice number






5600Location


Invoice number






Maintenance Record


20

Maintenance Record

6000Location


Invoice number






6400Location


Invoice number






Maintenance Record


21

Maintenance Record

6800Location


Invoice number






7200Location


Invoice number






Maintenance Record


22

Maintenance Record

7600Location


Invoice number






8000Location


Invoice number






Maintenance Record


23

Maintenance Record

8400Location


Invoice number






8800Location


Invoice number






Maintenance Record


24

Maintenance Record

9200Location


Invoice number






9600Location


Invoice number






Maintenance Record


25

Maintenance Record

10000Location


Invoice number






10400Location


Invoice number






Maintenance Record


26

Maintenance Record

10800Location


Invoice number






11200Location


Invoice number






Maintenance Record


27

Maintenance Record

11600Location


Invoice number






12000Location


Invoice number






Maintenance Record


28

Maintenance Record

12400Location


Invoice number






12800Location


Invoice number






Maintenance Record


29

Maintenance Record

13200Location


Invoice number






13600Location


Invoice number






Maintenance Record


30

Maintenance Record

14000Location


Invoice number






14400Location


Invoice number






Maintenance Record


31

Maintenance Record

14800Location


Invoice number






15200Location


Invoice number






Maintenance Record


32

Maintenance Record

15600Location


Invoice number






16000Location


Invoice number






Maintenance Record


33

Maintenance Record

16400Location


Invoice number






16800Location


Invoice number






Maintenance Record


34

Maintenance Record

17200Location


Invoice number






17600Location


Invoice number






Maintenance Record


35

Maintenance Record

18000Location


Invoice number






MAN Truck & Bus AG

Vogelweiherstraße 33

90441 Nürnberg

Germany

A member of the MAN Group

Printed in Germany 51.99597-8044

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